- Distilling Flare Recovery
The purpose of the project was to recover and treat all routine flared gas. Gasses routed to flare crossed through four sliding vane compressors and were reintroduced back into the plant for reuse. Our team started the final design in August 2010 and completed it in April 2011, providing engineering, procurement and expediting services. The projected was turned over to the client's operations on Dec. 7, 2011, and startup proceeded without difficulties, earning approval from the Environmental Protection Agency on Dec. 22, 2011.
Major equipment included four sliding vane compressors, four air-cooled heat exchangers, two inter-stage and two after-stage compressor coolers, a high pressure coker super-heater, a flare seal makeup cooler, a bulk lube oil storage tank, a glycol coolant skid, an inlet cooler knockout drum, and an after-cooler knockout drum. Equipment and pipe rack modules enabled expediting on the project. Burns & McDonnell developed the modular drawings and followed up by providing in shop inspection and oversight of the modular units. The project also included a 2,800-square-foot electrical building that was delivered in three modules and included variable frequency drives for the compressors and two high-voltage transformers, two medium-voltage transformers and two capacitors.
Once the gasses were compressed, they were reintroduced into the gas plant through approximately 5,000 feet of pipe. The owner did not want to provide low point drains that required maintenance, so the line was heated via a heat exchanger to keep the gas above the dew point. This eliminated the need for heat tracing and finding power sources throughout the plant.
To verify proper project installation and to make sure contractors' questions were handled expeditiously during the extremely tight construction schedule, the owner enlisted our team for construction support services. With the tight schedule, our team was on site to assure commissioning and startup proceeded as flawlessly as possible.
- Front end planning
- Final design
- Procurement and expediting
- Module design and delivery
- On-site construction support
The final design effort included:
- Developing all disciplines final designs
- Conducting design reviews and 3D electronic model reviews
- Conducting process hazard analysis
- Overseeing the process management of change
- Coordination with the owner's on-site area experts and inspectors
- Developing piping tie-in drawings
- Developing and evaluating bid packages for owner-purchased items including equipment, vessels, pumps, sample stations, instrumentation, piping fabrication, modules, capacitors, transformers, cable and cable tray
- Reviewing vendor drawings
- Coordinating, expediting and inspecting vendors on site
- Locating specialty materials for equipment fabrication
- Developing construction bid packages to expedite the construction activities